Method of parent welding partition matrix

ABSTRACT

A nondisassembling partition assembly comprising a partition matrix made up of intersecting first and second slotted plastic partitions, each of the partitions having at least one slot. The slots of the partitions are engaged with each other at a plurality of intersections. The matrix is held together in a nondisassembling relationship by at least one parent weld formed by heating an edge of the partitions at one or more intersections with one or more heat sources until the intersecting partitions become molten, removing the heat source or sources from edge of the intersecting partitions and allowing the partitions to cool. The parent welds formed by this process permanently secure the partitions together in the nondisassembling relationship without the use of any material other than the partitions themselves. A supporting net may be permanently secured to one edge of the partition matrix by either placing the net in contact with heated edges of the partitions while the edges of the partitions are molten and then allowing the edges of the partitions to cool, or by placing both the net and the edge of the matrix proximate a heat source to melt both and then when molten, distancing both from the heat source and allowing both to cool.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional application of patent application Ser.No. 08/713,988, filed Sep. 13, 1996, now U.S. Pat. No. 5,788,146, whichwas a Continuation-In-Part application of U.S. application Ser. No.08/600,589 filed Feb. 13, 1996 entitled Welded Partition Assembly (nowU.S. Pat. No. 5,732,876) and assigned to the assignee of thisapplication, which application is herein incorporated by reference inits entirety. The application which matured into U.S. Pat. No. 5,732,876was a Continuation-In-Part application of Ser. No. 08/559,619 filed Nov.20, 1995 entitled Recyclable Container Partition, (now U.S. Pat No.5,597,113) which is also herein being incorporated by reference in itsentirety.

FIELD OF THE INVENTION

The present invention relates to a nondisassembling partition assemblyfor dividing the space inside a container or box; more particularly to anondisassembling partition assembly made of slotted plastic partitions.

DESCRIPTION OF THE PRIOR ART

In the storage, shipment or display of parts or merchandise, it is acommon practice to divide the interior of a box or container into aplurality of individual cells. The interior of a box or container istypically separated by a series of dividers, one set of paralleldividers being orthogonal to a second set of dividers. The dividersseparate the interior of the container into a plurality of individualholding cells each of which is intended to hold a separate item fordisplay or shipment. The division of the interior of the box orcontainer helps prevent the items therein from contacting one anotherand breaking during shipping. The division or partitioning of thecontainer also aids in the loading and unloading of the items therein,as well as inventorying the contents of each box or container.

The dividers typically are slotted and arranged in an orthogonalrelationship to divide the interior of the box or container into adesired number of holding cells. The dividers are slotted in a mannerthat enables the dividers to engage with one another at the location ofthe slots so that the dividers form an orthogonal grid or matrix.Typically the dividers are made of the same material as the material ofthe box or container, plastic or paperboard. However, the dividers maybe constructed of any suitable material with sufficient rigidity toprevent the contents of the container from contacting one another andbeing damaged.

Disassembling traditional partition assemblies comprise a series ofindividual slotted dividers which mesh together in an orthogonal grid ormatrix. The assembly as a whole is generally collapsible but theindividual dividers of the assembly may be removed from the assemblyindividually and stacked. To disassemble the array or matrix of dividersone must lift one of the slotted dividers up out of the box orcontainer, disengaging its slots with the slots of the dividersorthogonal to it. Because the assembly is disassembling, the assemblymay be stored in much less space than if the assembly werenondisassembling. A problem with this type of partition assembly,though, is that if one desires to re-use the assembly one has tore-engage the slots of the dividers and then place the assembly inside abox or container. Additionally, this type of partition assembly issubject to inadvertent disassembly whenever parts are removed from thecells of the partition assembly.

A more desirable partition assembly for many applications is one that isnot fully disassembling with the individual dividers of the assemblyaffixed to each other. Such a nondisassembling assembly may be lifted asa whole out of a box without the operator worrying about the dividersseparating from one another.

Several U.S. patents disclose nondisassembling, collapsible partitionassemblies which separate the interior of a box or container into aplurality of cells. The collapsible divider assemblies disclosed inthese patents generally have a first set of dividers extending in onedirection intersecting orthogonally with a second set of dividersextending in a second direction. In many of these nondisassemblingassemblies, a portion of either the longitudinal or transverse divideris cut out at each intersection and permanently affixed to the adjacentintersecting divider in order to make the assembly nondisassembling. Inothers of these nondisassembling assemblies, a flap added to either thelongitudinal or transverse dividers is folded and permanently affixed tothe intersecting divider.

One such nondisassembling partition assembly is disclosed in U.S. Pat.No. 4,621,764 wherein slotted cross strips of a collapsible partitionassembly intersect and are joined to slotted longitudinal dividers.According to the disclosure of this patent, each of the cross strips hastabs cut from the center section of each cross strip adjacent theintersecting longitudinal divider, the tabs being folded into contactwith and adhered to the longitudinal dividers to prevent thelongitudinal dividers from separating from the cross strips.

Another nondisassembling slotted partition assembly is disclosed in U.S.Pat. No. 4,746,053. In this patent there is disclosed a nondisassemblingpartition assembly having a plurality of longitudinal slotted dividersinter-engaging a plurality of slotted transverse dividers. Triangularshaped tabs are cut and folded from the longitudinal dividers adjacentthe top of each slot of the divider. These tabs are spot welded, stapledor otherwise secured to the transverse dividers to prevent the partitionassembly from ever disassembling.

U.S. Pat. No. 3,942,709 discloses a slotted partition assembly having aplurality of parallel longitudinal dividers intersecting a plurality ofcross dividers or so called tying strips. The end portions of the tyingstrips are bent along score lines and secured to the longitudinaldividers by a glue bond so as to prevent disassembly of the assembledpartition assembly.

In each of these prior art patents, the longitudinal dividers aresecured to the transverse dividers at specific locations only, namelythose locations in which a portion of a divider has been cut or scoredand folded along a perforation. The folded portion is then spot welded,glued or otherwise secured to the adjacent intersecting partition ordivider. Such attachment or securement using tabs or folded portions ofthe dividers glued or otherwise secured to adjacent intersectingdividers is not always secure and may result in the tearing of the tabsand hence disassembly of the matrix. This method of securing theintersecting dividers is also costly due to the cost of cutting thetabs, assembling the partitions, folding the tabs and adhering orotherwise securing the tabs and adjacent partitions.

In each of these prior art patents, at the specific locations where thelongitudinal dividers are secured to the transverse dividers some sortof additional material is generally required to secure the dividerstogether. This additional material may be staples, glue, or additionalplastic material used to secure one portion of a divider to anintersecting divider. This additional material used to secureintersecting dividers adds to the cost of manufacture of the assemblyand may increase the time required for manufacture.

It therefore has been one objective of the present invention to providea method of manufacturing a non-disassembling partition assembly withoutthe use of any additional material other than the material of thepartitions themselves.

It has been another objective of the present invention to provide amethod of manufacturing a non-disassemblable partition assembly which isless costly than all heretofore known methods.

It has been a further objective of the invention to provide a method ofmanufacturing a non-disassemblable partition assembly which is secureand may not be easily disassembled.

It has been another objective of the present invention to provide adurable, sturdy, non-disassemblable partition assembly which is lesscostly to produce than prior disassemblable partition assemblies.

It has been another objective of the present invention to provide a lesscostly, nondisassemblable collapsible partition assembly in which thepartitions are made of plastic and are recyclable.

SUMMARY OF THE INVENTION

The nondisassembling partition assembly of the present invention whichaccomplishes these objectives comprises at least one first slottedpartition intersecting with at least one second slotted partition, bothfirst and second slotted partitions being made of plastic. The first andsecond slotted partitions are preferably made from the same identicalplastic material. The intersecting first and second slotted partitionsform a plurality of holding cells into which different parts are storedfor shipment or display.

Each first slotted partition has at least one slot extending inwardlyfrom an edge of the first slotted partition. Likewise each secondslotted partition has at least one slot extending inwardly from an edgeof the second slotted partition. Preferably the slots are evenly spacedin order to make the holding cells which are defined by the intersectingpartitions of identical dimensions. Each of the slots of the firstslotted partitions extends inwardly from an edge of the first slottedpartition to approximately the midpoint of the first slotted partition.Each of the slots of the second slotted partitions extends inwardly froman edge of the second slotted partition to approximately the midpoint ofthe second slotted partition.

The plastic partitions may be formed of a solid polyethylene orpolypropylene plastic material. Alternatively the partitions may be madeof double faced plastic, each slotted partition having two outer faceplies of plastic and a plurality of spacers between the face plies. Thespacers may be a plurality of dimples pressed from a middle ply ofplastic or alternatively the spacers may be a plurality of parallelevenly spaced corrugations, two adjacent corrugations defining a flute.The corrugations and flutes between the face plies of the partitions maybe vertically oriented or horizontally oriented. The distance betweenthe two face plies and the distance between the two adjacentcorrugations define the size of the flutes.

The first and second slotted partitions are arranged in a matrix.Preferably, the intersecting first and second slotted partitions aremade of the same identical plastic material. Each slot of a firstslotted partition is engaged with a slot of a second slotted partitionat an intersection. The partition matrix is held together in anassembled relation by a plurality of parent weldments of the sameidentical plastic material as the slotted partitions. For purposes ofthis application, the term "parent weld" or "parent weldment" refers toa weldment of two contacting plastic parts or partitions welded orsecured together without the use of any additional material other thanthe material of the parts or partitions themselves. In this application,each parent weldment is formed by heating portions of intersectingpartitions with a heat source. The heat source is placed in suchproximity to the contacting portions of the partitions so that heat fromthe heat source causes the portions of the partitions to become molten.The heat source is then distanced from the contacting and moltenportions of the partitions and the portions of the partitions allowed tocool, thereby creating a parent weld at one or more intersections. Theparent welds permanently secure the first slotted partitions to thesecond slotted partitions at the intersections by fusing theintersecting partitions together. Parent welds may exist at allintersections of the first and second slotted partitions along one edgeof the matrix or alternatively only at select intersections depending onthe type of heat source used.

Such a process of welding intersecting partitions together without theuse of any additional material other than the partitions themselves toform a nondisassembling partition is quick, economical and allows manyassemblies to be mass produced with low material and labor costs. Oncethe portions of the partitions are separated from the heat source andallowed to cool, the parent welds formed thereby exist only at one edgeof the matrix and preferably allow the matrix to be collapsible yetnondisassemblable. The capability of the matrix to collapse allows thematrix to be easily collapsed for shipment and then re-erected forreuse.

In order for the first slotted partitions to strongly bond withintersecting second slotted partitions along one edge of the matrix, thefirst and second slotted partitions preferably are of the same plasticmaterial. If the first and second slotted partitions are not the sameidentical plastic material a secure weld may be difficult to create byheating and cooling one edge of the matrix and the partition assemblymay not be easily recyclable after its useful life is expended.

An alternative embodiment of the present invention includes a supportingnet made of plastic attached to one edge of the partition assembly. Thisalternative embodiment may be formed one of two ways. The first methodof forming a nondisassembling partition assembly having a supporting netsecured to one edge of the assembly comprises intersecting a pluralityof first slotted partitions with a plurality of second slottedpartitions at a plurality of intersections thus creating a partitionmatrix. One edge of the partition matrix is placed proximate a heatsource until the edge of the partitions become molten. The heat sourceis then distanced from the edge of the matrix and a supporting net madeof plastic placed against the molten edge of the matrix. The latent heatretained by the molten edge of the matrix melts the supporting net tothe matrix and once allowed to cool the supporting net is permanentlysecured to the edge of the matrix. The supporting net may be made of anyplastic material and if sufficiently flexible will allow the matrix tocollapse without interfering with the collapsibility of the matrix. Thecapability of the matrix to collapse enables the assembly to be shippedor stored in a semi-flat condition and be reused when reerected.

An alternative method of forming a nondisassembling partition assemblyhaving a supporting net attached thereto comprises first placing thesupporting net proximate a heat source and allowing the supporting netto warm until it is in a semi-molten state. One edge of the partitionmatrix is then placed on the supporting net while the supporting net isstill proximate the heat source. The heat given off by the heat sourcepartially melts the edge of the partitions abutting the supporting netand partially melts the supporting net until both the supporting net andabutting edge of the matrix partitions are in a semi-molten state. Theheat source is then separated from the matrix which is now partiallymelted to the supporting net. Once allowed to cool, the supporting netis permanently attached to one edge of the partition matrix and theintersecting partitions fused together so as to make the assemblynondisassembling.

The supporting net acts as a bottom support or base, enabling itemsplaced in the individual holding cells of the assembly to rest upon andbe supported by the net and to be lifted out of the container housingthe nondisassembling partition assembly simultaneously with the removalof the nondisassembling partition assembly.

This method of securing a supporting net to a partition assembly isquick, easy and inexpensive. The intersecting first and second slottedpartitions are permanently secured to each other along one edge, makingthe assembly nondisassembling and also enhanced by a supporting netpermanently attached to one edge of the partition assembly without usingany additional material or tools. dr

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a plurality of first slotted partitionsand a plurality of second slotted partitions before their engagementwith each other to form a partition assembly and before the assembly isplaced on a heated surface;

FIG. 2A is an enlarged perspective view of a portion of the partitionassembly of FIG. 1 after the assembly has been heated by a heatedsurface and made nondisassembling, the partitions having a dimpledplastic ply between two face plies;

FIG. 2B is an enlarged perspective view of a portion of the partitionassembly of FIG. 1 after the assembly has been heated by a heatedsurface and made nondisassembling, the partitions having verticallyoriented corrugations;

FIG. 3 is a perspective view of an alternative embodiment of the presentinvention having a supporting net secured to one edge of the partitionassembly; and

FIG. 4 is a series of diagrammatic side elevational views illustrating amethod of manufacturing the nondisassembling partition assembly using ahot planar surface.

FIG. 5 is a perspective view of a plurality of hot air nozzles placeddirectly above a plurality of intersections to heat intersectingpartitions.

FIG. 6 is a perspective view of a partition matrix supported by aconveyor belt with the conveyor belt passing over a heat source in orderto heat one edge of the partition matrix.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to the drawings and particularly to FIG. 1, there isillustrated in disassembled form a nondisassembling partition assemblyof the present invention for dividing the space inside a container. Thepartition assembly 10 comprises a plurality of parallel first slottedpartitions 12 intersecting with a plurality of parallel second slottedpartitions 14.

Each first slotted partition 12 has a planar top edge 16, a planarbottom edge 18 and two opposed side edges 20. Likewise each secondslotted partition 14 has a planar top edge 22, a planar bottom edge 24and two opposed side edges 26.

Each first slotted partition 12 has at least one slot 28 which extendsdownwardly from the top edge 16 of the first slotted partition 12 toapproximately the midpoint of the first slotted partition 12. The slots28 may be evenly spaced apart in order that the individual holding cellsof the partition assembly may be evenly sized. Alternatively, the slots28 of the first slotted partitions 12 may be unevenly spaced in order toform holding cells of the partition assembly of differing sizes toaccept different sized parts. The slots 28 are shown as being verticalbut may be horizontal if the partition assembly 10 is placed on edge.

Each second slotted partition 14 has at least one slot 30 extendingupwardly from the bottom edge 24 of the second slotted partition 14 toapproximately the midpoint of the second slotted partition 14. The slots30 of the second slotted partitions 14 may also be evenly spaced inorder so that the holding cells of the partition assembly may be evenlysized. Alternatively, the slots 30 may be unevenly spaced in order toform holding cells of the partition assembly of differing sizes adaptedto accept different sized parts. The slots 30 are shown as beingvertical but may be horizontal if the partition assembly 10 is placed onedge.

Each of the first and second slotted partitions 12, 14 are made ofplastic and are preferably made of the same identical plastic. Thepartitions may be made of solid plastic or of double faced plastichaving a plurality of spacers between the two faces. The spacers may bea plurality of dimples punched out of a middle ply of plastic or aplurality of corrugations. The corrugations may be vertically orhorizontally oriented. As best illustrated in FIGS. 2A and 2B, eachslotted partition may have two face plies 32 and 34 which are parallelto one another. Between the face plies 32, 34 are a plurality ofspacers. As illustrated in FIG. 2A, the spacers may be a plurality ofdimples 36 protruding from a middle ply of plastic 38. Alternatively thespacers may be a plurality of evenly spaced corrugations 40 between theface plies 32 and 34. The corrugations may be vertically or horizontallyoriented. FIG. 2B illustrates vertically oriented corrugations 40between the face plies 32 and 34 of each of the partitions. The spacersmay be any other configuration as long as they separate the two faceplies 32, 34.

Although the partitions of the assembly may be solid plastic or doublefaced plastic with a plurality of spacers therebetween, usually eachassembly is made up of first and second partitions of identicalmaterial. In other words, all of the first slotted partitions and all ofthe second slotted partitions of one matrix or assembly 10 arepreferably of identical material in accordance with the practice of thisinvention. For example, in FIG. 2A the first and second slottedpartitions are both made of double faced plastic having a plurality ofdimples 36 between the face plies 32 and 34. However, the intersectingfirst and second slotted partitions may be different. For example, thefirst slotted partitions may have dimples 36 between two face plies andthe second slotted partitions have vertically oriented corrugations 40between the face plies.

To practice the method of this invention and form a nondisassemblingpartition assembly, a plurality of first slotted plastic partitions 12are arranged on edge in a spaced parallel manner. As illustrated in FIG.1, slots 28 of the first slotted partitions 12 extend inwardly from thetop edge of the first slotted partitions with a bottom edge of the firstslotted partitions abutting the planar heated surface 42. A plurality ofsecond slotted partitions 14 are lowered downwardly in an interlockingarrangement with the first slotted partitions 12 to form a partitionmatrix. As illustrated in FIG. 1, the slots 30 of the second slottedpartitions 14 extend upwardly from the lower edge of each of the secondslotted partitions 14. Each slot 28 of a first slotted partition 12engages with a slot 30 of a second slotted partition 14 at anintersection 44. The second slotted partitions 14 are lowered downwardlyin locking engagement with the first slotted partitions 12 until thebottom edge 24 of the second slotted partitions is co-planar with thebottom edge 18 of the first slotted partitions.

Once the matrix is completely assembled by engaging the slots of thepartitions, the matrix is lowered downwardly until it rests on theheated surface 42. One of the edges of the matrix, usually the bottomedge 46 of the matrix abuts the heated planar surface 42 and reststhereon. The bottom edge of the matrix 46 remains on the planar heatedsurface for a sufficient length of time until the lower edges 18, 24 ofthe partitions become molten. The heat melts the plastic of thepartitions. Once the bottom edge 46 of the matrix is in a molten statethe heated planar surface 42 is removed from the matrix, usually bylifting the matrix away from the heated surface. The edge of the matrix46 is then allowed to cool creating a parent weld at each intersectionpermanently securing intersecting partitions in a nondisassemblingrelationship. The parent weld is formed without the use of anyadditional material other than the material of the partitionsthemselves.

As best seen in FIGS. 2A and 2B the edges of the matrix partitions whichhave been heated, after cooling, generally have a ridge 48 extendinglaterally from the faces of the partitions. Thus, a cross-section of thefirst and second slotted partitions are in the form of a "T" with ahorizontal planar edge 50 formed as the result of the heating of theedges of the partition against the heated planar surface. Along thelengths of all the partitions which were against the heated planarsurface 42 is the planar flat edge 50 having two outwardly extendingridges 48 which extend outwardly from the sidewalls 32, 34 of the firstand second slotted partitions.

Preferably the first and second slotted partitions are made of the sameidentical plastic material in order that the parent welds 54 formed as aresult of placing the edge 46 of the matrix against the heated planarsurface are solid and strong and the complete assembly may be easilyrecycled after the useful life of the assembly is expended. However, thefirst and second slotted partitions may be made of different plasticmaterials. A weld formed at an intersection of a first slotted partition12 and a second slotted partition 14 of differing plastic compositionswill generally not be as strong as a weld formed between a first andsecond slotted partition of the same identical plastic material.

An alternative embodiment of the present invention is illustrated inFIG. 3 which includes a supporting net 56. The supporting net 56 isattached to one edge of the partition assembly while the heated edge 46of the matrix is still in a molten state. The supporting net 56 becomespermanently attached to the edge of the matrix 46 when the edge of thematrix 46 is allowed to cool once separated from the heating surface 42.

The supporting net 56 itself consists of crisscrossing individual netmembers 58 which are made of plastic, preferably of the same compositionas the composition of the partitions in order to aid in therecyclability of the partition assembly 10 as a whole. The net materialis preferably polyethylene or polypropylene but may be any otherflexible net material.

As illustrated in FIG. 4, the method by which this alternativeembodiment of a nondisassembling partition assembly with a securing netis manufactured is similar to the method of manufacturing thenondisassembling partition assembly without the net. A plurality offirst slotted partitions 12 are lined up in a spaced parallel mannerwith their slots 28 extending downwardly from the top edge thereof. Aplurality of second slotted partitions 14 are moved downwardly as shownby the arrows 60 in FIG. 4 until the slots of the second slottedpartitions engage the slots of the first slotted partitions at aplurality of intersections. The partitions thus form a matrix orassembly which at this point may still be disassembled.

The partition matrix is then lowered downwardly onto a hot plate orheated surface 42 so that one edge of the matrix abuts the surface 42 ofa hot plate. Heat from the hot plate melts the one edge 46 of the matrixpartitions to a molten state. Then the matrix as a whole is removed fromthe heated surface 42 of the hot plate and placed downwardly on top of asupporting net 56 so that the heated edge of the matrix 46 abuts the topsurface of the supporting net 56. Retained heat of the molten edge 46 ofthe matrix partially melts the individual members 58 of the supportingnet 56. The net and matrix are then allowed to cool, thereby permanentlysecuring the first and second intersecting partitions and permanentlysecuring the supporting net 56 to the edge 46 of the matrix. Thesupporting net 56 is thereby permanently attached to the bottom edge ofthe partition assembly 10 and forms a bottom or base for the completeassembly. This configuration of partition assembly with a net bottomenables individual articles placed inside the holding cells of thepartition assembly 10 to be lifted out of the box or container with thepartition assembly 10 when the partition assembly 10 is lifted out of abox or container. Depending on the material of the supporting net thepartition assembly 10 may or may not be collapsible.

An alternative method of constructing a nondisassembling partitionassembly having a supporting net attached thereto involves a slightmodification of the above-described method. Using this method ofassembly the intersecting first and second slotted partitions areengaged with one another to create a matrix just as in theabove-described method. However, rather than the lower edge of thematrix being placed directly onto the heated surface 42 of the hotplate, the supporting net 56 is placed directly onto the hot platebefore the matrix is placed on the hot plate. The supporting net 56 islaid onto the hot plate and allowed to become soft and partially molten.The matrix of partitions is then placed on top of the supporting netwhich is still on top of the hot plate. The bottom edge 46 of the matrixabuts in face to face relation the top surface of the supporting net 56and heat from the hot plate partially melts the lower edge of the matrixpartitions and the supporting net 56. Once the supporting net and loweredge of the intersecting partitions are sufficiently heated and molten,the matrix and supporting net are lifted away from the hot plate 10 withthe supporting net 56 attached to the lower edge 46 of the matrix. Thenet and matrix are then allowed to cool sufficiently to create aplurality of welds at the intersections securing the first and secondslotted partitions together in a nondisassembling fashion and alsocreating permanent welds between the individual members 58 of thesupporting net 56 and the lower edges of the partitions at a pluralityof locations where net members 58 cross the partitions. These welds canbe seen in FIG. 3 and are numbered 62.

An alternative method of constructing the present invention utilizing adifferent heat source is illustrated in FIG. 5. Using this method,intersecting partitions are secured together with parent welds createdby hot air being blown through one or more nozzles 68. A plurality ofhot air lines 64 connect a hot air source 66 to a plurality of nozzles68 which lie directly above one or more intersections 44 of thepartitions 12, 14. Hot air is blown through each nozzle 68 downwardly onto the top edges 22 of the partitions at the intersections 44 in orderto heat the plastic of the partitions until the top edges of thepartitions become molten and the plastic of the intersecting partitionsflows together. Once molten, the nozzles 68 either one at a time orsimultaneously are distanced from the intersections 44 or the hot air iscut off in order to prevent further heating of the intersections. Themolten plastic at the intersections 44 is then allowed to cool creatinga parent weld (not shown) at each of the intersections. The parent weldspermanently secure the first and second partitions 12, 14 to each other.Utilizing this method of manufacture not all intersections need beheated in order to create a non-disassembling matrix. A parent weld maybe created at select intersections only by placing a nozzle 68 aboveselected intersections 44 of the matrix, such as for example at the fourcorner intersections 44 of the matrix. One or more nozzles 68 may bemoved relative to the matrix 70 or alternatively the matrix 70 may bemoved relative to stationary nozzles 68.

FIG. 6 illustrates another method used to secure intersecting partitionsto each other with parent welds. Employing this method all intersections44 of a matrix are bound together with parent welds rather than onlyselect intersections being parent welded. One entire edge of a matrix isheated rather than select intersections. Rather than an edge of a matrix70 directly touching a heat source or hot plate, the matrix 70 issupported on a conveyor belt 72 which passes in the direction of arrow74 allowing the matrix 70 to pass above a heat source 76. The conveyorbelt 72 is made up of a crisscrossing members, such as metal mesh 78allowing heat from the heat source 76 to penetrate through the conveyorbelt 72 and heat the lowermost edge of the matrix 70. This lower edge ofthe matrix (most proximate the heat source) is heated until the edges ofthe individual partitions become molten. As the conveyor belt moves thematrix 70 along in the direction of arrow 74, the matrix 70 is distancedfrom the heat source 76 and the edge of the matrix which had been moltenwhen the matrix was directly above the heat source is now allowed tocool, creating a plurality of parent welds 54 at each of theintersections 44 of partitions 12, 14. The heat source 76 may be anysource of sufficient heat, including but not limited to hot air, aradiant hew, or heat from a hot plate. Utilizing this method ofmanufacture, many partition assemblies may be made nondisassemblingquickly, easily, and at a low cost without utilizing any additionalmaterial other than the material of the partitions themselves.

While I have described only a few embodiments of my invention, I do notintend to be limited except by the scope of the following claims:

What is claimed is:
 1. A method of forming a nondisassemblingintersecting partition matrix with a supporting net, said matrixcomprising at least one first slotted partition intersecting with atleast one second slotted partition, each first slotted partition havingat least one slot extending inwardly from an edge of the first slottedpartition, each second slotted partition having at least one slotextending inwardly from an edge of the second slotted partition, saidmethod comprising the steps of:engaging said at least one slot of saidat least one first slotted partition with said at least one slot of saidat least one second slotted partition at an intersection to form amatrix; heating an edge of said matrix, placing a supporting net incontact with said edge of said matrix, allowing said matrix andsupporting net to cool to secure the matrix and the supporting net toeach other.
 2. The method of forming a nondisassembling intersectingpartition matrix with a supporting net of claim 1 wherein saidpartitions of said matrix are heated until molten before the supportingnet is secured to the matrix.
 3. A method of forming a nondisassemblingintersecting partition matrix, said matrix comprising a plurality offirst slotted partitions intersecting with a plurality of second slottedpartitions, each first slotted partition having a series of slots, eachslot extending inwardly from an edge of the first slotted partition,each second slotted partition having a series of slots each slotextending inwardly from an edge of the second slotted partition, saidmethod comprising the steps of:engaging the slots of the first pluralityof slotted partitions with slots of the second plurality of slottedpartitions at intersections to form a matrix; heating an edge of saidmatrix with a heat source partially melting said edge of said matrix,placing a supporting net on said edge of said matrix, allowing said edgeof said matrix to cool to create welds permanently securing theintersecting partitions in a nondisassembling relationship and securingsaid supporting net to the intersecting partitions.
 4. The method offorming a nondisassembling intersecting partition matrix of claim 3wherein said supporting net is placed on said edge of said matrix whilesaid edge is molten.
 5. The method of forming a nondisassemblingintersecting partition matrix of claim 3 wherein said partitions andsaid supporting net are of the same generally plastic composition forease of recyclability.
 6. A method of forming a nondisassemblingpartition matrix, said matrix comprising a plurality of first slottedpartitions intersecting with a plurality of second slotted partitions,each first slotted partition having a series of slots, each slotextending from an edge of the first slotted partition towards anopposite edge of said first slotted partition, each second slottedpartition having a series of slots, each slot extending from an edge ofthe second slotted partition towards an opposite edge of the secondslotted partition, said method comprising the steps of:engaging a slotof a first slotted partition with a slot of a second slotted partitionat an intersection to form a matrix, heating a supporting net with aheat source partially melting said supporting net, placing an edge ofsaid matrix against said supporting net, separating said matrix andsupporting net from said heat source, allowing said matrix andsupporting net to cool to permanently secure the intersecting partitionsin a nondisassembling relationship and secure said supporting net tosaid intersecting partitions.
 7. The method of forming anondisassembling partition matrix of claim 6 wherein said supporting netis proximate said heat source when said edge of said matrix is placedagainst the supporting net.
 8. A method of forming a nondisassemblingpartition assembly having a supporting net secured to a partitionmatrix, said partition matrix comprising a plurality of first slottedpartitions intersecting with a plurality of second slotted partitions,each first slotted partition having a series of slots extending inwardlyfrom an edge of the first slotted partition, each second slottedpartition having a series of slots extending inwardly from an edge ofthe second slotted partition, said method comprising the stepsof:engaging one of the slots of the first slotted partition with one ofthe slots of the second slotted partition at an intersection to form amatrix; heating an edge of the matrix with a heat source to partiallymelt coplanar edges of said partitions, placing said edge of the matrixagainst the supporting net, allowing said partitions to cool, therebypermanently securing the supporting net and matrix in a nondisassemblingrelationship.
 9. The method of forming the nondisassembling partitionassembly of claim 8 wherein heating said edge of the matrix comprisesplacing said edge on a heat source.
 10. A method of forming anondisassembling partition assembly having a supporting net secured to apartition matrix, said partition matrix comprising a plurality of firstslotted partitions intersecting with a plurality of second slottedpartitions, each first slotted partition having a series of slotsextending inwardly from an edge of the first slotted partition, eachsecond slotted partition having a series of slots extending inwardlyfrom an edge of the second slotted partition, said method comprising thesteps of:engaging one of the slots of the first slotted partition withone of the slots of the second slotted partition at an intersection toform a matrix; placing the supporting net directly on a heat source inorder to partially melt said supporting net, placing the matrix on thesupporting net, lifting said matrix with said supporting net attached tosaid matrix away from said heat source and allowing said matrix andsupporting net to cool, thereby permanently securing the supporting netand matrix together.
 11. The method of forming the nondisassemblingpartition assembly of claim 10 wherein the supporting net is on the heatsource when the matrix is placed on the supporting net.
 12. A method offorming a partition assembly having a bottom, said methodcomprising:heating an edge of said partition assembly, contacting saidedge of said partition assembly with a supporting net, allowing saidedge of said partition assembly and said supporting net to cool tosecure the edge of said partition assembly and said supporting nettogether.
 13. The method of claim 12 wherein said heating said edge ofsaid partition assembly comprises placing coplanar edges of partitionson a heated surface to partially melt said coplanar edges of saidpartitions.
 14. A method of forming a nondisassembling intersectingpartition matrix with a supporting net, said matrix comprising at leastone first slotted partition intersecting with at least one secondslotted partition, each first slotted partition having at least one slotextending inwardly from an edge of the first slotted partition, eachsecond slotted partition having at least one slot extending inwardlyfrom an edge of the second slotted partition, said method comprising thesteps of:engaging said at least one slot of said at least one firstslotted partition with said at least one slot of said at least onesecond slotted partition at an intersection to form a matrix; heatingone of said matrix and said supporting net, placing a supporting net incontact with said matrix, allowing said matrix and supporting net tocool to secure the matrix and the supporting net to each other.